Supply roll run-out warning apparatus



J. D'ANGELO Nov. 15,- 1966 SUPPLY ROLL RUN-OUT WARNING APPARATUS 2 Sheets-Sheet 1 Filed March 18, 1964 Nov. 15, 1966 J. D'ANGELO 3,286,249

SUP-FLY ROLL RUN-OUT WARNING APPARATUS Filed March 1 8, 1964 2 Sheets-Sheet 2 v a-d6 #1 F i I 19 I 5 92 93 INVEIGTOR United States Patent 3,286 249 SUPPLY ROLL RUN-OUT WARNING APPARATUS Joseph DAngelo, Wyckotf, N.J., assignor to Roto Bag Machine Corporation, Paramus, N.J., a corporation of New York Filed Mar. 18, 1964, Ser. No. 352,828 6 Claims. (Cl. 340-259) The invention relates to supply roll run-out warning apparatus for automatically providing a warning or control signal a short time period prior to the moment when a supply roll of sheet material will run out. More particularly this invention relates to such apparatus which is positioned adjacent to one end face of a supply roll of sheet material and which provides a signal when the depth ofthe sheet material still remaining wound on the supply roll has become reduced to a predetermined level.

In many types of existing automatic machines which handle, process or utilize large quantities of sheet material, this sheet material is supplied from a large roll which contains the sheet material as a continuous web wound upon a hollow core. This sheet material may be any type of thin flexible web material, for example, such as paper, cellophane, plastic film, foil, package wrapping material, and the like. The hollow core'of the roll is supported on a spindle shaft in the machine and the roll is held in position against a cheek plate at one end of the shaft. As the material is fed into the machine, the diameter of the roll decreases so that a progressively diminishing depth of the sheet material remains wound on the core;

As soon as the roll has run out, the machine is stopped by the operator, and the empty core is removed from the support shaft and is replaced by a full roll. In many applications the machine operator joins the leading end of the new roll to the trailing end of the existing web of material, for example, as by the use of pressure-sensitive adhesive tape. Then he restarts the machine and runs it slowly until the joined region of the web has been fed completely through the machine, at which time the machine is sped up to its normal feed rate.

If the operators attention is diverted, for example, he may be in charge of several machines, then it is possible for the supply roll in one machine to run out before he has an opportunity to see it and stop the machine. Thereafter, he must laboriously thread the leading end of the web of sheet material from the new roll through the machine. This hand threading operation wastes substantial time. Moreover, if the sheet material is being used in conjunction with other material or product, for example, as in packaging machine, then there may occur substantial wastage of product during the interval between run-out of the material and shut-down of the machine for reloading. Also, there is the problem that occasionally the end face of the new roll of material and cheek plate are not positioned on the support shaft firmly abutting against one another so that proper feeding of the sheet material does not occur, causing edge jamming or improper overlapping of the sheet material in the machine.

Among the many advantages of the illustrative embodialerted by the initial signal and he prepares to slow down and stop the machine for reloading when the second signal occurs.

In addition one of the embodiments of this warning apparatus is adapted to be used to shut down the operation of the machine in the event that the operator does not take appropriate action as the supply roll is just about to run out.

Among the further advantages of the embodiments of the invention as shown are those resulting from the fact that the warning apparatus mechanically senses the end face of the wound sheet material in the supply roll so that when the diameter of the roll is reduced below certain predetermined limits then a sequence of signals is provided. This mechanical sensing of the end face of the roll renders the apparatus capable of operating with all kinds of rolls of sheet material regardless of the characteristics of the material, that is, whether it is opaque or pellucid, conductive or nonconductive, and so forth. Also, this apparatus is adapted to be included conveniently as part of the cheek plate assembly so as to rotate with the supply roll as the web is payed off from the roll.

Furthermore, during loading of a new supply roll into a machine this warning apparatus provides an indication showing when the end face of the new supply roll and the cheek plate have been positioned in the desired closely adjacent relationship and also providing a warning when they have not been properly positioned.

In the illustrative embodiments of the invention as described herein the apparatus provides both a visual and an audible signal at an adjustable period prior to run-out. Then at a later adjustable period just prior to run-out the audible signal ceases but the visual signal continues so as to aid in identifying which one of several machines is about to run out of its supply of material.

It is an object of this invention to provide supply roll run-out warning apparatus convenient and easy to use in a wide variety of different applications and reliable in operation.

In this specification and in the accompanying drawings are described and shown illustrative embodiments of the supply roll run-out warning apparatus of this invention, and various modifications thereof are indicated, but it is to be understood that these are not to be construed as exhaustive nor limiting of the invention, but on the contrary are given for purposes of illustration in order that others skilled in the art may fully understand the invention and the many ways of applying this invention in practical use.

The various objects, aspects, and advantages of the present invention will be more fully understood from a consideration of the following specification in conjunction with the accompanying drawings, in which:

FIGURE 1 is a sectional view of the supply roll runout warning apparatus, and this view includes fragmentary portions of the cover;

FIGURE 2 is an axial sectional view of the supply roll, its support shaft and the cheek plate together with the warning apparatus, this view being taken along the lnie 2-2 of FIGURE 1;

FIGURE 3 is an elevational view of a portion of the inner surface of the cheek plate, being a view taken along the line 33 of FIGURE 2 and showing the roll sensing means;

FIGURE 4 is an enlarged view of a portion of FIG- URE 2;

FIGURE 5 is a schematic circuit diagram of one embodiment of the invention;

FIGURE 6 is a schematic circuit diagram of another embodiment of the invention for automatically shutting down a machine just prior to run-out of its supply roll; and

FIGURE 7 is a view of the battery and its mounting, a detail View taken along the line 77 of FIGURE 1.

Referring to the drawings in greater detail, it is noted that the supply roll, which is generally indicated at 10 in FIGURES 2 and 3, includes a tubular core 12, for example, of heavy stiff cardboard, and a wide web of sheet material 14 which is tightly wound upon this core 12. In this illustrative example the sheet material 14 is shown as being a wound web of plastic sheet packaging material, for example, cellophane, but it is to be understood that this sheet material may be any one of a great variety of different sheet materials, as dis-cussed in the introduction further above. The original full diameter of the supply roll 10 is indicated in FIGURE 2 by a dash and dot outline at 14'. As shown in FIGURE 3, during utilization of this roll, the web of material 14 is fed from the roll along a path 15 into an automatic machine, for example, such as a wrapping machine, and the whole supply roll 10 including its core 12 rotates about a support shaft 16 as the material pays off from the roll.

In order to hold the supply roll the shaft 16 is mounted on a frame member 17. A large circular flat cheek plate 18 (FIGURE 1) has a central hole 20 (FIGURES 1 and 2) fitting around a core holding assembly 21 on the shaft 16, said assembly including a sliding tube 23 and a rotating tube 25. This cheek plate 18 forms a part of a cheek plate assembly 22 including an annular housing cover 24 which is attached to the plate 18 by means of a pair of mounting posts 26 (FIGURE 2) rigidly aflixed to the plate 18 as by screws 27. The cover 24 is removably secured to the mounting posts 26 by fastening means 28 (FIGURE 1) shown as a pair of thumb screws. The cheek plate assembly 22 is suitably attached onto a flange 29 of the revolving sleeve so that the whole assembly 22 is free to rotate with the supply roll 10.

The supply roll run-out warning apparatus 30 is enclosed in the annular space between the plate 18 and cover 24, with parts of this warning apparatus 30 being mounted on the back surface of the plate 18 and with other parts mounted on the inner surface of the cover 24.

Inviting attention also to FIGURE 5 it is noted that the warning apparatus 30 includes an audible signal device 32, shown as an electric horn, an indicator light bulb 33, first and second roll-end-face sensing switches 34 and 35, a source of electrical energy 36, shown as a battery, and a suitable on-off switch 37, for example a slide-type switch. The contacts of the first switch 34 are normally closed while those of the second switch 35 are normally open. It is noted that these switches are actuated by first and second sensing plungers 38 and 39, respectively, and the first plunger 38 is located at a greater distance from the axis of the roll than the second plunger.

In operation, when the end face (FIGURE 2) of the supply roll is properly positioned in closely adjacent relationship with the cheek plate 18, then the plungers 33 and 39 are depressed by the end face 40 so that the contacts 41 (FIGURE 5) of the switch 34 are open and the contacts 42 of the switch 35 are closed. For clarity of illustration, as will be understood, FIGURE 2 shows more space between the end face 40 and the cheek plate 18 than is normally present when the supply roll is properly positioned. The switches 34 and 35 are of the short-travel actuation type wherein a small displacement of the plungers 38 and 39 will open or close these switches, for example, they are shown as microswitches.

As shown in FIGURE 4, the ends of the plungers 38 and 39 are covered by a flexible diaphragm cover 43 which is secured to the inner surface of the cheek plate 18 so as to provide a smooth surface for the sheet material to pay out past these plungers. Also, the plungers themselves are of relatively large diameter with smoothly rounded ends toward the roll-end-face 40, thus avoiding any snagging of the edge of the sheet material 14.

If the supply roll 10 is not positioned sufficiently closely adjacent to the cheek plate 18 when the machine is being loaded, then the contacts 41 remain closed, and the light 33 remains on. The circuit for energizing the light 33 is traced from a terminal 44 of the electrical source 36 through the now-closed contacts 41, through a lead 45 and a lead 46 to the on-off switch 37 and thence to the light 33, with a return circuit through a ground connection 47 to the plate 18. It is noted that the battery 36 is in a holder 48 which serves to provide a ground connection to the plate 18 for one terminal of the battery with the other terminal 44 being insulated from the plate 18.

When the new supply roll is properly positioned snugly adjacent to the cheek plate 18, then the contacts 41 are opened and the light 33 goes out.

During operation of the machine utilizing the sheet material 14, as the depth H of the material is reduced below the position of the end of the first plunger sensing means 38, then this plunger is released to close contacts 41, turning on the warning light 33. The horn 32 is also turned on at this same moment through its connection 49, because the contacts 42 are still being held closed by the end face of the roll 10. Thus, a combined audible and visual signal is given, at an appropriate time, for example two minutes before run-out.

Later at an appropriate period, for example one minute before run-out, when the depth H of the material 14 is diminished below the position of the end of the second plunger sensing means 39, then the second switch 35 is released so that its contacts 42 are opened to shut off the horn 32. However, the visual signal 33 advantageously remains on so as to attract attention to the roll which is nearing run-out.

The switches 34 and 35 are mounted on individual brackets 50 held by clamp screws and lockwashers 52 so that the respective positions of the switches can be adjusted for adjusting the plungers 38 and 39 along generally radially extending elongated openings 54. In this way the radial spacing A between the two plungers and the radial distance B between the second plunger and the outer surface of the core 12 are adjusted so as to provide the desired predetermined time periods for the respective signals which are adjusted in accordance with the thickness of the sheet material 14 and its rate of pay-out, so as to provide adequate warning.

The indicator light 33 is mounted in a socket 56 (FIG- URE 1) adjustably secured to the cheek plate 18 by a slotted bracket 57 held by a clamp screw and lock washer 58. A transparent plastic rod 60 serves as a visual indicator signal device by transmitting light from the bulb 33 out through the perimeter of the cover 24 to a position where the light can readily be observed beyond the rim 62 of the plate 18. This rod 60 is rigidly attached to the cover 24 by a threaded sleeve 64 and a pair of jam nuts 66. The bulb 33 is adjusted to be aligned with the axis of visual signal rod 60 and the outer end 68 of the rod is beveled to enhance the visibility of the light signal 70 which issues therefrom. A suitable material for this rod 60 is methyl methacrylate, e.g. Lucite.

As the cheek plate assembly 22 rotates, the light signal is clearlv visible; not only is the end of the rod 60 illuminated, but also the light flashes onto nearby portions of the machinery as the assembly 22 rotates.

As mentioned above, the light 33 remains on until a new roll is properly loaded onto the shaft 16. In the event that the shaft 16 is to remain empty for awhile, then the switch 37 may be turned off so as to save the battery.

The warning apparatus embodiment 30A of FIGURE 6 is similar to that shown in FIGURES 1-5, and corresponding reference numerals are used for elements performing corresponding functions in the two systems. In addition, the system of FIGURE 6 automatically shuts off the main drive motor 75 for the machine which is utilizing the sheet material 14, in the event that the operator does not happen to take appropriate action prior to run-out of the supply roll. The motor 75 has one side connected to an appropriate source of electrical power 76 by means of a power line 77. The other side of this motor is connected by a line 78 to a movable armature 79 of a relay 80 which has a normally closed set of contacts 81 completing the circuit through the contacts 82 of a holding relay 84 to a line 85 and main switch 86 to the source 76.

In operation when the horn 32 is energized, the solenoid coil 87 of the relay 80 is energized so as to move its armature 79 and open the contacts 81. The circuit for energizing the coil 87 is traced from the switch 37 through a lead 88 to a slip ring 89 on the cover 24 and thence through a brush 90 which is connected to the coil 87.

As soon as the relay contacts 81 are opened, the holding coil 91 of relay 84 is deenergized so as to open the contacts 82 and to close the contacts 92, thus completing a circuit through a lead 93 to a thermal time-delay relay 94 for maintaining the motor 75 energized. This time delay relay 94 includes a resistance heater 96 and a bimetal armature element 98 with a pair of normally closed contacts 99. After an appropriate delay period, for example a minute and a half, the armature 98 moves to open the contacts 99, and a mechanical latch 100 latches the armature 98 in its open position so as to stop the motor 75. When the operator wishes to restart the motor 75 he raises the control 102 so as to reclose the holding relay 84 and then releases the latch 100.

From the foregoing it will be understood that the supply roll run-out warning apparatus described herein as illustrative embodiments of the present invention are well suited to provide the advantages set forth and that all matter hereinbefore set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense and that in certain instances some of the features of the invention may be used without a corresponding use of other features or may be modified into equivalent elements, all without departing from the scope of the invention as defined by the following claims.

What is claimed is:

1. Supply roll run-out warning apparatus for providing a warning signal at a desired time period prior to the run-out of a supply roll of sheet material, said warning apparatus including a rotatable cheek plate assembly adapted to be placed near one end face of the roll to rotate with the roll as the web of sheet material is payed out from the roll, sensing means mounted on said cheek plate assembly for rotation therewith and having a smoothly rounded end for engaging a point on the end face of the roll at a predetermined distance from the inner limit of said roll and for providing for the sheet material to pay out past said sensing means as the cheek plate rotates with the roll, and signal apparatus controlled by said sensing means for providing a signal when the depth of material in said roll is reduced below said predetermined distance.

2. Supply roll run-out Warning apparatus for providing a warning signal at a desired time period prior to the runout of a supply roll of sheet material, said warning apparatus including a rotatable cheek plate having an inner surface for placement near one end face of the roll for said cheek plate to rotate with the roll as the web of sheet material is payed off from the roll, said check plate having an opening therein from its outer surface to said inner surface, sensing means mounted for rotation with said cheek plate and including sensing means extending through said opening having a smoothly rounded end for engaging a point on the end face of the roll at a predetermined radial depth from the inner limit of said roll for the sheet material to pay out past said sensing means without snagging, and signal apparatus controlled by said sensing means for providing a signal when the depth of material in said roll is reduced below said point.

3. Supply roll run-out warning apparatus for providing a sequence of warning signals at desired time periods prior to the run-out of a supply roll of sheet material, said warning apparatus including rotatable support means adapted to be placed near one end face of the roll for rotation with the roll, a plurality of sensing means mounted on said support means and having smoothly rounded ends for engaging a plurality of points on the end face of the roll at different distances from the axis of said roll for the sheet material to pay out freely past the revolving support means and a visible and an audible signal apparatus controlled by said sensing means for simultaneously providing a visible and an audible signal when the depth of material in said roll is reduced below an outer of said points and subsequently discontinuing the audible signal while continuing the visible signal when the depth of material in said roll is reduced below an inner one of said points.

4. Supply roll run-out warning apparatus for providing a sequence of warning signals at desired time periods prior to the run-out of a supply roll of sheet material, said warning apparatus including a rotatable cheek plate adapted to be placed near one end face of the roll to rotate with the roll as the material is payed off therefrom, a plurality of sensing means mounted on said cheek plate for engaging a plurality of points on the end face of the roll at different distances from the axis of said roll, a cover detachably secured to said cheek plate for rotation together with said cheek plate, a light and an audible signal apparatus enclosed within said cover, a transparent rod element extending from said light out through said cover for providing a distinctly visible signal as said cheek plate and cover rotate, said light and audible signal apparatus being controlled by said sensing means for simultaneously providing a visible and an audible signal when the depth of material in said roll is reduced below an outer of said points and subsequently discontinuing the audible signal while continuing the visible signal when the depth of material in said roll is reduced below an inner one of said points.

5. Supply roll run-out warning apparatus for providing a sequence of warning signals at desired time periods prior to the run-out of a supply roll of sheet material, said warning apparatus including rotatable mounting means adapted to be placed near one end face of the roll, first and second sensing means mounted on said mounting means for engaging first and second points on the end face of the roll at different radial distances from the axis of the roll, said first point being at a greater radial distance than said second point, first and second switches on said rotatable mounting means controlled by said first and second sensing means, respectively, said first switch being normally closed and said second switch being normally open, an audible warning device and a source of electrical energy on said rotatable mounting means, circuit means connecting both of said switches and said source in circuit in serial relationship with said audible warning device for sounding said audible warning device when the depth of the material in said roll is diminished below said first point and for shutting off said audible warning device when said depth is diminished below said second point, a visual warning device on said rotatable mounting means, and circuit means connecting said visual warning device and said source in circuit in serial relationship with said first switch for energizing said visual warning device when said depth is diminished below said first point.

6. Supply roll run-out warning apparatus as claimed in claim 4 and wherein said rotatable cheek plate assembly includes a flexible diaphragm secured to the inner surface of the cheek plate adjacent to the end face of the roll and covering said sensing means providing a smooth surface adjacent to the roll for the sheet material to pay out.

References Cited by the Examiner UNITED STATES PATENTS Peter 340-380 Kemper 340-327 X Warren. Freitas 340-327 X Boomer 340-380 Koechel 340-260 X NEIL C. READ, Primary Examiner.

R. GOLDMAN, Assistant Examiner. 

2. SUPPLY ROLL RUN-OUT WARNING APPARATUS FOR PROVIDING A WARNING SIGNAL AT A DESIRED TIME PERIOD PRIOR TO THE RUNOUT OF A SUPPLY ROLL OF SHEET MATERIAL, SAID WARNING APPARATUS INCLUDING A ROATATABLE CHEEK PLATE HAVING AN INNER SURFACE FOR PLACEMENT NEAR ONE END FACE OF THE ROLL FOR SAID CHEEK PLATE TO ROTATE WITH THE ROLL AS THE WEB OF SHEET MATERIAL IS PAYED OFF FROM THE ROLL, SAID CHEEK PLATE HAVING AN OPENING THEREIN FROM ITS OUTER SURFACE TO SAID INNER SURFACE, SENSING MEANS MOUNTED FOR ROTATION WITH SAID CHEEK PLATE AND INCLUDING SENSING MEANS EXTENDING THROUGH SAID OPENING HAVING A SMOOTHLY ROUNDED END FOR ENGAGING A POINT ON THE END FACE OF THE ROLL AT A PREDETERMINED RADIAL DEPTH FROM THE INNER LIMIT OF SAID ROLL FOR THE SHEET MATERIAL TO PAY OUT PAST SAID SENSING MEANS WITHOUT SNAGGING, SAID SINAL APPARATUS CONTROLLED BY SAID SENSING MEANS FOR PROVIDING A SIGNAL WHEN THE DEPTH OF MATERIAL IN SAID ROLL IS REDUCED BELOW SAID POINT.
 4. SUPPLY ROLL RUN-OUT WARNING APPARATUS FOR PROVIDING A SEQUENCE OF WARNING SIGNALS AT DESIRED TIME PERIODS PRIOR TO THE RUN-OUT OF A SUPPLY ROLL OF SHEET MATERIAL, SAID WARNING APPARAUTS INCLUDING A ROTATABLE CHEEK PLATE ADAPTED TO BE PLACED NEAR ONE END FACE OF THE ROLL TO ROTATE WITH THE ROLL AS THE MATERIAL IS PAYED OFF THEREFROM, A PLURALITY OF SENSING MEANS MOUNTED ON SAID CHEEK PLATE FOR ENGAGING A PLURALITY OF POINTS ON THE END FACE OF THE ROLL AT DIFFERENT DISTANCES FROM THE AXIS OF SAID ROLL, A COVER DETACHABLY SECURED TO SAID CHEEK PLATE FOR ROTATION TOGETHER WITH SAID CHEEK PLATE, A LIGHT AND AN AUDIBLE SIGNAL APPARATUS ENCLOSED WITHIN SAID COVER, A TRANSPARENT ROD ELEMENT EXTENDING FROM SAID LIGHT OUT THROUGH SAID COVER FOR PROVIDING A DISTINCTLY VISIBLE SIGNAL AS SAID CHEEK PLATE AND COVER ROTATE, SAID LIGHT AND AUDIBLE SIGNAL APPARATUS BEING CONTROLLED BY SAID SENSING MEANS FOR SIMULTANEOUSLY PROVIDING A VISIBLE AND AN AUDIBLE SIGNAL WHEN THE DEPTH OF MATERIAL IN SAID ROLL IS REDUCED BELOW AN OUTER OF SAID POINTS AND SUBSEQUENTLY DISCONTINUING THE AUDIBLE SIGNAL WHILE CONTINUING THE VISIBLE SIGNAL WHEN THE DEPTH OF MATERIAL IN SAID ROLL IS REDUCED BELOW AN INNER ONE OF SAID POINTS. 